Configurable welding table and force indicating clamp

ABSTRACT

Disclosed is a configurable table that uses configurable mounting pieces to mount a work piece on the configurable table at a predetermined location. The configurable table includes a fixed portion of a mounting clamp that can engage a rotatable portion of a mounting clamp on a positioner or other device. The positioner can then rotate the configurable table and work piece to various orientations for performing horizontal welds, using robotic welders, as well as machining and cutting. The configurable table can also be used for initial fabrication, cutting, or working, which eliminates the need for separate fabrication and finish welding tables.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of and claims priority to U.S.application Ser. No. 13/941,270, filed Jul. 12, 2013, which applicationis based upon and claims priority to U.S. provisional application Ser.No. 61/671,032, filed Jul. 12, 2012, entitled “Configurable WeldingTable and Force Indicating Clamp,” which applications are bothspecifically incorporated herein by reference for all that they discloseand teach.

BACKGROUND

Automated welding techniques using robotic welders and large positionershave greatly increased the quality of industrial welding. Greaterreliability can be provided using automated welding techniques. Inaddition, the welds can be completed rapidly, without the use of highlypaid and highly skilled welders.

In addition, the use of positioners to position a piece for welding hasalso provided for high quality welds. Welds that are performed when thepiece is disposed in a horizontal position allow the weld to properlyflow into an opening and properly fill the space in the opening. Largepositioners are capable of rotating large pieces into positions, so thathorizontal, high quality welds can be performed.

SUMMARY OF THE INVENTION

An embodiment of the present invention may therefore comprise a methodof configuring a work piece for performing a work task comprising:providing a configurable table having a plurality of mounting locationsdisposed on a first portion of the configurable table and a firstportion of a rotatable mounting clamp disposed on a second portion ofthe configurable table; providing a plurality of configurable mountingpieces having mounting connectors for mounting the mounting pieces atthe mounting locations disposed on the first surface of the configurabletable, the configurable mounting pieces adapted to position and mountthe work piece in a predetermined location on the configurable table;providing a second portion of the rotatable mounting clamp that isdesigned to engage the first portion of the rotatable mounting clampwith sufficient force so that the configurable table can be rotated withthe work piece mounted on the configurable table in the predeterminedposition with sufficient force so that the work piece does notsubstantially move with respect to the configurable table.

An embodiment of the present invention may further comprise a system forconfiguring a work piece for a work task comprising: a configurabletable having a plurality of mounting locations disposed on a firstportion of the configurable table; a first portion of a rotatablemounting clamp disposed on a second portion of the configurable table; aplurality of configurable mounting pieces that are adapted to positionand securely mount the work piece to the first portion of theconfigurable table; a plurality of mounting connectors that engage themounting locations disposed on the first portion of the configurabletable to securely mount the configurable mounting pieces to the firstportion of the configurable table; a second portion of the rotatablemounting clamp and that engages the rotatable mounting clamp that isconfigured to engage the first portion of the rotatable mounting clampwith sufficient force to rotate and invert the work piece.

An embodiment of the present invention may further comprise a mountingdevice for mounting a work piece to a configurable table comprising: abase plate that is adapted to secure the mounting device in a desiredlocation on the configurable table; a clamping lever that is configuredto engage and apply a tightening device that engages the base plate andthe clamping lever that creates a force on the clamping lever to holdthe work piece; an integral deflection gauge that is engaged by theclamping lever that measures compression of a spring to provide ameasure of the force applied to the work piece.

An embodiment of the present invention may further comprise a clamp forsecuring a work piece to a configurable table comprising: a base thatsecures the clamp to the configurable table at a desired location on theconfigurable table; a shaft mounted to the base; a clamping lever thathas a clamping portion for clamping the work piece to the configurabletable, a deflection portion and an opening that engages the shaft sothat the clamping lever can rotate on the shaft to a first position sothat the clamping lever does not interfere with the work piece duringmounting of the work piece on the configurable table, and to a secondposition so that the clamping portion engages the work piece; a springthat compresses in response to a force applied from the shaft that istransferred to the clamping lever and to the work piece; a deflectiongauge disposed in the clamp to measure compression of the spring toprovide a measure of the force that is transferred to the work piece.

An embodiment of the present invention may further comprise a crowderfor mounting and positioning a work piece to a configurable tablecomprising: a base plate that is adapted to secure the crowder to theconfigurable table; a crowder body housing; a threaded shaft blockdisposed in the crowder body so that the shaft block can move laterallyin the crowder body; a threaded shaft that rotatably engages the shaftblock and applies a force on the work piece in response to rotation ofthe shaft which causes threaded shaft block to translate laterally; aspring that compresses in response to lateral translation of thethreaded shaft block; a deflection gauge that measures the lateraltranslation of the shaft block to provide a measurement of the forceapplied to the work piece.

An embodiment of the present invention may further comprise a system forconfiguring a work piece for a work task comprising: a configurabletable having a plurality of mounting locations disposed on a firstportion of the configurable table; a plurality of configurable mountingpieces that position and securely mount the work piece to the firstportion of the configurable table with sufficient force to hold the workpiece to the configurable table without substantial movement when thework piece is rotated; a plurality of mounting connectors that engagethe plurality of configurable mounting pieces and the mounting locationsdisposed on the first portion of the configurable table to securelymount the plurality of configurable mounting pieces to the first portionof the configurable table.

An embodiment of the present invention may further comprise a mountingdevice for mounting a work piece to a table comprising: a base platethat is configured to secure the mounting device in a desired locationon the table; a clamp that applies a force on the work piece and securesthe work piece to the base plate; an integral force detector thatprovides an indication of the force generated by the clamp; an integralgauge that displays the force generated by the gauge.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic isometric view of an embodiment of a configurablewelding table attached to a positioner.

FIG. 2 is a side view of the configurable welding table of FIG. 1mounted on a positioner.

FIG. 3 is a side view of the configurable welding table of FIG. 1 thatis disconnected from a positioner.

FIG. 4 is an isometric view of the top portion of the configurablewelding table of FIG. 1.

FIG. 5 is an isometric bottom view of the configurable welding table ofFIG. 1.

FIG. 6 is a top perspective view of the configurable welding table ofFIG. 1 with a plurality of configurable mounting pieces located on theconfigurable welding table.

FIG. 7 is an isometric view of an embodiment of a configurable mountingclamp that comprises one of the configurable mounting pieces.

FIG. 8 is a transparency view of the embodiment of a configurablemounting clamp of the embodiment of FIG. 7.

FIG. 9 is a side sectional view of the embodiment of the configurablemounting clamp illustrated in FIGS. 7 and 8.

FIG. 10 is an isometric sectional view of the configurable mountingclamp illustrated in FIGS. 7, 8 and 9.

FIG. 11 is an isometric view of an embodiment of a crowder thatcomprises one of the configurable mounting tools.

FIG. 12 is a schematic cutaway view of the crowder illustrated in FIG.11.

FIG. 13 is a schematic cutaway view of the crowder illustrated in FIGS.11 and 12.

FIG. 14 is an isometric view of an embodiment of a datum that comprisesone of the configurable mounting tools.

FIG. 15 is a side isometric view of the embodiment of a datumillustrated in FIG. 14.

FIG. 16 is an isometric view of an embodiment of a combined clamp andcrowder.

FIG. 17 is an isometric view of an embodiment of a horizontal datum.

FIG. 18 is an isometric view of an embodiment of a work piece mounted ona configurable table.

FIG. 19 is an isometric view of a custom mounting clamp used to clampthe work piece illustrated in FIG. 18.

FIG. 20 is an isometric view of an embodiment of a configurable tablethat is rotated on a single axis by two positioners.

FIG. 21 is an isometric view of an embodiment of a head end or tail endclamp 2100

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 is an embodiment of a configurable table 106 mounted on apositioner 100. The configurable table 106 can be used for mounting workpieces for welding, machining, and other functions, known to thoseskilled in the art of manufacturing large devices. The configurabletable 106 can be configured with a plurality of configurable mountingpieces 108 that securely fasten a work piece (not shown) for welding orother functions. For example, the configurable table 106 can be used toclamp pieces for initial fabrication, as well as final fabrication.Positioner 100 can rotate the work piece, that is mounted on theconfigurable table 106, to various positions by rotation on an axisthrough openings 102, 104. Welding can be performed by robotic weldersthat extend into areas of the work piece (not shown) for performingeither finished welds, or initial assembly welds.

It has been found by those skilled in the art that welds performed onsubstantially horizontal surfaces allow the weld material to flow evenlywithin the weld opening to form a consistent and uniform weld betweentwo or more pieces of metal. Positioner 100, illustrated in FIG. 1, canrotate the work piece (not shown) mounted on the configurable table 106to various positions, so that the robotic welders can perform welds onthe work piece when the weld is substantially horizontal. In thismanner, the use of the configurable table 106 and the positioner 100allows consistent and uniform welds to be performed by automated weldingrobots.

The configurable mounting pieces 108, illustrated in FIG. 1, aresecurely connected to the configurable table 106. By way of exampleonly, one inch threaded bolts can be used to bolt the configurablemounting pieces 108 to the configurable table 106, so that various workpieces can be clamped to the configurable table, so that there issubstantially no movement of the work pieces as the positioner is moved.In that regard, the configurable mounting pieces 108 can be located toattach various types, sizes and shapes of work pieces to theconfigurable table 106, so that the center of gravity of the work pieceis centered on the positioner 100. This allows the positioner 100 tooperate in an efficient manner. Of course, the work piece can be mountedon any position on the table, if desired. However, mounting of the workpiece at the center of gravity allows the work piece to be rotated withless force.

FIG. 2 is a schematic side view of the positioner 100 and configurabletable 106 of the embodiment of FIG. 1. As shown in FIG. 2, theconfigurable mounting pieces 108 comprise various devices for mountingand clamping the work piece (not shown) to the configurable table 106.For example, the configurable mounting pieces 106 comprise a datum 112,a combined crowder and clamp 114, another combined crowder and clamp116, and an additional datum 110. The datums 110, 112 provide locationpoints for accurately mounting the work piece to the configurable table106. The combined crowder and clamps 114, 116 crowd the work piece to adatum and clamp the work piece to the configurable table 106. Mountingclamp 118 functions to releasably attach the configurable table 106 tothe positioner 100. Any type of mounting clamp can be used and canattach the configurable table 106 to positioner 100 at a centeredlocation, as shown in FIG. 2, or at any location, including the ends ofthe configurable table 106, as shown in FIG. 20. Mounting clamps caninclude quick release mounting clamps, such as disclosed in, but notlimited to, the clamp disclosed in U.S. Patent Ser. No. 61/535,402,filed Sep. 16, 2011, by John Schoening, (now U.S. Pat. No. 9,095,957issued Aug. 4, 2015) entitled “Rotary Actuated Axial Clamp,” which isspecifically incorporated herein by reference for all that it disclosesand teaches.

The configurable table 106, illustrated in FIG. 2, can be configuredwith the proper configuring mounting pieces 108 and the work piece priorto mounting the configurable table 106 to the positioner 100. In thismanner, the configurable table 106 can be placed on a floor andsupported by the feet 124, 126 that are disposed on the bottom portionof the configurable table 106. As indicated herein, initial fabricationof a work piece (not shown) can occur prior to mounting the configurabletable 106 on the positioner 100. This allows the configurable table 106to function both as an initial fabrication table, as well as a finalfabrication table, so as to create a more efficient process forfabricating work pieces and reducing the work flow process, leading tofaster and better fabrication.

FIG. 3 is another side view of the embodiment of FIG. 2, illustratingthe configurable work table 106 disconnected from the positioner 100. Asillustrated in FIG. 3, the fixed portion 122 of the mounting clamp 118is disposed on the configurable table 106. The fixed portion 122 is lessexpensive than the moveable portion 120 of the mounting clamp 118 thatis located on the positioner 100. As such, costs are reduced, sincemultiple different configurable tables, such as configurable table 106,can be constructed and mounted to the moveable portion 120 of mountingclamp 118 on the positioner 100. Accordingly, multiple work tables canbe configured with work pieces while a work piece is being welded, so asto reduce fabrication time, and increase overall efficiency of thesystem. As mentioned above, any type of mounting clamp can be used toclamp configurable table 106 to positioner 100, including quick releasemounting clamps, or non-quick release clamps. Quick release mountingclamps have the advantage of speeding the overall work flow process.

FIG. 4 is a schematic isometric top view of an embodiment of aconfigurable table 106. As illustrated in FIG. 4, the configurable table106 has a top plate 130 that may be fabricated from steel or othersimilar material. A plurality of threaded openings 128 are formed in thetop plate 130. By way of example only, the threaded openings may bethreaded openings that accept a one inch threaded bolt. Of course, anytype of attachment can be used to attach configurable mounting pieces108 to configurable table 106, including non-threaded openings thatprovide a way of mounting the configurable table 106 with a sufficientforce so that the configurable mounting pieces do not move whenpositioner 100 rotates a work piece. The threaded openings 128, or otheropenings, are disposed in a predetermined pattern, such as the matrix ofrows and columns illustrated in FIG. 4. Of course, any desired patternof threaded openings can be formed in the top plate 130. In that regard,the pattern of threaded openings 128 can be labeled, so that theposition of the configurable mounting pieces 108 can be identified andmounted on the top plate 130 at the proper location for each work piece.The top plate 130 is attached to a plurality of supports, such assupport 132. FIG. 4 also illustrates foot 124 and foot 126 that supportthe configurable table 106 when the configurable table 106 is placed ona surface. Fixed portion 122 of the mounting clamp 118 is alsoillustrated in FIG. 4. The fixed portion 122 forms a fixed piece mountedto the configurable table 106, that is adapted to fit with the moveableportion 120 of the mounting clamp 118. Hooks 140, 142, 144 and 146 areused to lift the configurable table 106 and position the configurabletable 106 for attachment to the positioner 100 or other device, usingthe mounting clamp 118. Calibration features 148, 150, 152, 154 arelocated in the corners of the top plate 130. The calibration features148-154 allow the robotic welder to position itself with respect to theconfigurable table 106, so that the robotic welder can be accuratelylocated with respect to the work piece. The calibration features 148-154can comprise any desired type of calibration feature, including holes,studs or simply a marking on the top plate 130.

FIG. 5 is an isometric bottom view of the configurable table 106. Asillustrated in FIG. 5, there are four feet connected to the bottomportion of the configurable table 106, i.e., foot 124, foot 126, foot136, foot 138. Feet 124, 126, 136, 138 extend beyond the fixed portion122 of the mounting clamp 118, so that when the configurable table 106is placed on feet 124, 126, 136, 138, there is clearance between thefixed portion 122 and the surface, so that no damage occurs to fixedportion 122. As illustrated in FIG. 5, the fixed portion 122 is securelyattached to the supports 134 of the configurable table 106. The fixedportion 122 is centrally mounted on the bottom portion of theconfigurable table 106, so that the center of gravity of theconfigurable table 106 is centrally disposed on the moveable portion 120of the mounting clamp 118. The central mounting of the fixed portion 122of clamp 118, on the bottom portion of the configurable table 106, alsoallows work pieces to be centered on the configurable table 106, whilemaintaining the center of gravity of the work piece at a centrallocation on the configurable table 106. Again, the fixed portion 122 canbe disposed at any location on configurable table 106. Supports 134 areformed in a pattern and are securely attached to the bottom of the topplate 130, in any desired manner, such as by welding. The supports areformed in a pattern and welded together, so that the supports do notinterfere with the threaded holes in the top plate 130. The fixedportion 122 provides the tabs that allow the rotatable portion 120 torotate and clamp the fixed portion 122 in the manner described in U.S.Patent Application Ser. No. 61/535,402, filed Sep. 16, 2011, by JohnSchoening (now U.S. Pat. No. 9,095,957 issued Aug. 4, 2015), entitledRotary Actuated Axial Clamp, which is specifically incorporated hereinby reference for all that it discloses and teaches.

FIG. 6 is a schematic isometric view illustrating the configurable table106 with a plurality of configurable pieces 108 attached to the topsurface of top plate 130. As shown in FIG. 6, the configurable pieces108 are disposed in various locations on top plate 130 and are attachedto the top plate 130 with threaded bolts, or other attachment devices,that engage the threaded openings 128, or other types of openings. Ofcourse, other ways of attaching the configurable pieces 108 to the topplate 130 can be used, as well known by those skilled in the art. Theconfigurable pieces 108 are located at positions on the top plate 130 toclamp the work piece in the desired location on the configurable table106 for welding, cutting or other functions. Various types ofconfigurable pieces 108 can be used to accurately locate the work pieceon the top plate 130 of the configurable table 106, so that roboticdevices (not shown) can accurately perform the work task, whether thatwork task is welding, cutting, or other work task. The various mountinglocations, which are shown as the threaded openings 128, provide a largeamount of variability and flexibility in mounting the work piece on theconfigurable table 106. In general, however, it is desirable to mountthe work pieces so that the center of gravity of the work piece iscentrally located on configurable table 106, as close as possible, toreduce the forces required to turn and rotate the work piece andminimize forces on positioner 100.

FIG. 7 is a schematic isometric view of an embodiment of a mountingclamp 700. As illustrated in FIG. 7, a clamping lever 702 is coupled toa base 716 with a threaded shaft 714. Nut 712 exerts pressure on theclamping lever 702, which results in a clamping force to hold the workpiece 726 (FIG. 9) between the clamping portion 708 and the clampingplate 718 as explained in more detail below. The clamping portion 708,as well as the clamping plate 718, can be made of a hardened steel, sothat high clamping forces can be generated to hold the work piecebetween the clamping portion 708 and the clamping plate 718. Spring 702holds the clamping lever 702 apart from base 716, so that a flange, orother portion, of a work piece 726 (FIG. 9) can be easily disposedbetween the clamping portion 708 and clamping plate 718. In this manner,the operator that is clamping the work piece 726 (FIG. 9) in themounting clamp 700 does not have to lift the clamping lever 702, whichmay be quite heavy. During the process of mounting the work piece (notshown) in the mounting clamp 700, the clamping lever 702 can be rotatedso that the work piece can be vertically placed onto the clamping plate718 without interference from the clamping lever 702. The clamping lever702 can then be rotated back into the position illustrated in FIG. 7 andthe nut 712 tightened, i.e., rotated on the threaded shaft 714 to forcethe clamping lever 702 toward the base 716 until the clamping portion708 of the clamping lever 702 creates a sufficient amount of pressure onthe work piece 726, as explained in more detail below, to adequatelyhold the work piece 726 in a secure manner on the mounting clamp 700.The amount of clamping force that is desired to be generated by amounting clamp, such as mounting clamp 700 illustrated in FIG. 7, can bedetermined and selected based upon the forces that are expected to becreated by the work piece on the mounting clamp, as the configurabletable, such as configurable table 106, is rotated by a positioner, suchas positioner 100, with the work piece mounted by the mounting clamp 700on the configurable table. In that regard, it is desirable to have apreselected preloading force, i.e, clamping force, that is created bythe configurable mounting pieces 108 in FIG. 6, including the mountingclamp 700, that exceeds the forces that are created by the work piece onthe clamps during positioning and rotation of the work piece. Certainly,the preloading force of each clamp should exceed the portion of theweight of the work piece 726 that is being supported by each of theclamps, e.g., the mounting clamps 700. In addition, moment loadingcreated when the work piece 726 is rotated by the configurable table 106to certain positions, such as sideways positions, as well as momentumchanges create additional forces that far exceed the simple weight ofthe work piece 726. If any of these forces exceed the clamping force ofany particular clamp, e.g., the mounting clamp 700, the work piece 726can move relative to the configurable table 106, which can causeadditional problems. For example, a robotic welder must accuratelylocate the position of a weld and perform the welding at the prescribedposition. If the work piece 726 moves relative to the configurable table106, accurate positioning of the weld may not occur. Further,overloading of a clamp, e.g., the mounting clamp 700, that is notpreloaded to a particular force can cause movement of the metal in theclamp, which may cause fatigue. Clamps may prematurely fail as a resultof fatigue that occurs because of improper preloading. In one example,if a work piece weighs 5,000 lbs., each of the clamps, e.g., themounting clamps 700, that are used to hold a work piece 726 on theconfigurable table 106 may be preloaded to a force of 15,000 lbs., sothat no movement occurs when the work piece 726 mounted on theconfigurable table 106 by the mounting clamps 700 of the configurabletable mounting pieces 108 is rotated to any particular position by apositioner, such as positioner 100 in FIG. 1.

In that regard, the application of a predetermined amount of torque onnut 712 may result in greatly different amounts of force being appliedto the work piece 726 between the clamping portion 708 and clampingplate 718 (FIG. 9), as empirically determined during the use of variousclamping devices. In other words, the torque on nut 712 is not a goodindicator of the clamping force created by mounting clamp 700 on workpiece 726 (FIG. 9). In order to accurately determine the clamping force,the mounting clamp 700, illustrated in FIGS. 7-10, uses a deflectiongauge 706, which accurately measures the clamping force created betweenthe clamping portion 708 and clamping plate 718 as explained in moredetail below. Referring now primarily to FIG. 9, as the nut 712 isrotated on the threaded shaft 714 to force the clamping lever 702downwardly (as viewed on the drawing paper) toward the base 716, theclamping portion 708 will eventually move into contact with the workpiece 726, which is positioned on the clamping plate 718 and inhibitsany further movement of the clamping portion 708 toward the base 716.Therefore, further rotation of the nut 712 on the threaded shaft 714 toforce the clamp lever 702 farther downward toward the base 716 causesthe clamp lever 702 to pivot under the nut 712, which acts as a fulcrum713 facilitated by the dished washer 715 interfacing with the nut 712,so that the deflection portion 710 of clamping lever 702 pushes thedeflection piston 730 against a spring resistance force F_(S) of thedefection spring 724 (e.g., Belleville washer springs). The springresistance force F_(S) of the deflection spring 724 is applied by thedeflection piston 730 to the deflection portion 710 of the clampinglever 702, whereupon the spring resistance force F_(S) is thentransferred by the clamping lever 702, constrained by the fulcrum 713,to the clamping portion 708 of the clamping lever 702, which applies theclamping force F_(C) to the work piece 726. In other words, the springresistance force F_(S) is applied by the clamping lever 702 to clamp thework piece 726 to the clamping plate 718. Further tightening of the nut712 onto the clamping lever 702 causes further downward deflection ofthe deflection portion 710 of the clamp lever 702, which causes furthercompression of the deflection spring 724 by the deflection piston 730.Such further compression of the deflection spring 724 increases thespring resistance force F_(S) on the deflection portion 710 of theclamping lever 702, which results in a proportional increase in theclamping force F_(C) applied by the clamping portion 708 of the clampinglever 702 to the work piece 726. A deflection plate 722 is attached to,or a part of, the deflection piston 730 so that the deflection plate 722moves with the deflection piston toward and away from the base 716. Thedeflection gauge 706 measures the downward movement of the deflectionplate 722, thus also the downward movement of the deflection piston 730and the deflection of the deflection spring 724, which is substantiallyproportional to the spring resistance force FS generated by thedeflection spring 724 on the deflection portion 710 and to the resultingclamping force F_(C) applied by the clamping lever 702 to the work piece726. Accordingly, the clamping force F_(C) applied by the clampingportion 708 to the work piece 726 is a function of the spring resistanceforce F_(S) of the deflection spring 724 (e.g., Belleville washersprings). Since the threaded shaft 714 is shown as mounted insubstantially the center portion of the clamping lever 702 in theexample mounting clamp 700 in FIGS. 7-9, the lever arm between thedeflection portion 710 and the fulcrum 713 is substantially the samelength as the lever arm between the fulcrum 713 and the clamping portion708 of the clamping lever 702, whereby the amount of spring resistanceforce F_(S) generated by the deflection spring 724 on the deflectionportion 710 is substantially equal to the amount of clamping force F_(C)created by the clamping portion 708 on the work piece 726 (FIG. 9) thatis placed between the clamping portion 708 and the clamping plate 718. Aspring, or spring washers, such as Belleville washers (collectivelyreferred to as the deflection spring 724), that provides a substantiallylinear response of spring resistance force F_(S) to deflection in therange of forces created by the clamping lever 702 can be used, asdescribed below, to control the clamping force F_(C) applied by themounting clamp 700 to a work piece 726. The substantially linearresistive force response of the spring 724 to deflection, thusdeflection of the deflection piston 730 and deflection plate 722,enables a substantially linear measurement of the clamping force F_(C)applied by the clamping lever 702 to the work piece 726 by measurementof the deflection of the deflection piston 730 or deflection plate 722,which corresponds to deflection, e.g., compression, of the deflectionpiston 730. The deflection gauge 706 measuring such deflection can beeasily calibrated to provide an accurate reading on deflection gauge 706of the clamping force F_(C) applied by the clamping lever 706 to thework piece 726 as a function of deflection. Deflection gauge 706 can becalibrated as a force indicating display, for example, by providing arotatable cover plate that indicates the desired clamping force F_(C) tohold the work piece 726, to be applied by rotating the nut 712 asexplained above. For example, a force of 15,000 pounds may be anadequate clamping force to hold a work piece. The face of the deflectiongauge can be rotated to a pre-marked location, so that when a force of15,000 pounds is generated, the indicator of the deflection gauge 706falls within a green range, or other indicated range, on the dial of thedeflection gauge 706. In this manner, easy calibration can be performedby the user by simply rotating the cover plate of the deflection gauge706 to the proper preset location for the desired force, and the nut 712can be rotated until the indicator falls within the green range.

FIG. 8 is an isometric view of the embodiment of the mounting clamp 700similar to FIG. 7, but with the housing 728 (FIGS. 7 and 9) around thedeflection gauge 706 removed in FIG. 8 to reveal the deflection pin 720,the deflection plate 722, the Belleville washers 724, the deflectionpiston 730, and the proximity sensor or limit switch 732 in relation tothe deflection portion 710 of the clamping lever 702 and the deflectiongauge 706. The deflection portion 710 of the clamping lever 702 engagesthe deflection plate 722. The deflection plate 722 forms a portion of,or is connected to, the deflection piston 730. Belleville washers 724,or other spring devices, that provide a linear response in the desiredforce range, are disposed adjacent to the deflection piston 730. Whenforce is applied by the deflection portion 710 of clamping lever 702 tothe deflection plate 722 and deflection piston 730, the Bellevillewashers 724 are compressed. The amount of deflection of the deflectionplate 722 is substantially linearly proportional to the deflection ofthe Belleville washers 724, or other spring device as explained above.The deflection pin 720 of the deflection gauge 706 is disposed on thebottom portion of the deflection plate 722. The deflection pin moves asthe deflection plate 722 moves downwardly. The deflection pin 720 causesthe indicator on the deflection gauge 706 to rotate, indicating theamount of deflection of the deflection plate 722 on the indicator of thedeflection gauge 706. The amount of deflection indicated on thedeflection gauge 706 is proportional to the force of the deflectionportion 710 on the deflection plate 722, as long as the Bellevillewashers 724, or other spring devices, are operating in the linear rangeof forces that are desired to be measured by the deflection gauge 706.In other words, the orientation of Belleville washers 724, and thenumber of Belleville washers 724, are selected to provide a linearresponse in a desired force range, such as from 5,000 to 20,000 pounds,in one example. Of course, the spring resistance force can be varied byvarying the number and orientation of washers, as well as the springstrength, so that different forces can be measured by the deflectiongauge 706. As set forth above, marking indicators can be provided on thebezel of the deflection gauge 706, as well as the housing of thedeflection gauge 706, so that the bezel can be rotated to provide anindication of a desired force generated by clamping lever 702 byaligning the markings on the bezel and the housing. For example, if adesired force is 15,000 pounds, the bezel of the deflection gauge 706can be rotated to be aligned with a marking on the housing indicating15,000 pounds. A green portion can be placed on the face of thedeflection gauge 706 to indicate when a force of 15,000 pounds isgenerated. In this manner, accurate measurement of the force can becreated using a standard deflection gauge.

FIG. 8 also illustrates a proximity sensor or limit switch 732, that canbe optionally used in the mounting clamp 700, and may be used toreplace, or use in conjunction with, the deflection pin 720 anddeflection gauge 706. The proximity sensor/limit switch 732 can sensethe location of the deflection plate 722 and thereby determine the forcethat has been applied by the deflection portion 710 on the deflectionplate 722. In addition, a limit switch may be used to automaticallyindicate when the deflection plate 722 has moved sufficiently togenerate the desired force. At that point, an indicator may provide anindication that the required force has been created, so that a user nolonger has to tighten the nut of the mounting clamp 700. This may be inthe form of an LED, or other visual indication, including mechanicalvisual indicators. Further, a limit switch 732 may provide an electricalsignal to stop an automated operation of tightening the mounting clamp700. For example, the limit switch may send a signal to stop a hydraulicor pneumatic force generator (not shown), which causes an automaticcessation of rotation of the nut 712, or other control. The device 732can function either as a proximity switch or a limit switch, or as both.

FIG. 9 is a sectional view of the mounting clamp 700. As illustrated inFIG. 9, the threaded shaft 714 is mounted in, and secured to, the base716. Nut 712 rotates on the threaded shaft 714 and generates a forceagainst clamping lever 702. Spring 704 creates a force between the base716 and clamping lever 702 sufficient to maintain the clamping lever 702in a position so that a gap exists between the base 716 and the clampinglever 702. Spring 704 is sized to simply offset the weight of theclamping lever 702. As torque is applied to the nut 712, the clampinglever 702 moves downwardly and creates a force between the deflectionportion 710 of the clamping lever 702 on deflection plate 722 whileclamping the work piece 726 between the clamping portion 708 of theclamping lever 702 and the clamping plate 718. Again, since the threadedshaft 714 in the example mounting clamp 700 in FIGS. 7-9 is centrallydisposed in the clamping lever 702, tightening the nut 712 creates asubstantially even force at the deflection portion 710 on the deflectionplate 722 and at the clamping portion 708 on the workpiece 726. Clampingportion 708 creates the clamping force on work piece 726, which isclamped between the clamping portion 708 of the clamping lever 702 andthe clamping plate 718. The clamping plate 718 is mounted on the base716 of the mounting clamp 700. As explained above, the deflection plate722 forms a portion of, or is connected to, the deflection piston 730.The deflection piston 730 is mounted in the housing 728. In addition,Belleville washers 724 are also disposed in the housing 728 below thedeflection piston 730. Centering pin 736 centrally locates thedeflection piston 730 and deflection plate 722 in the housing 728.Deflection gauge 706 is mounted so that deflection pin 720 is disposedagainst the deflection plate 722. When the deflection plate 722 deflectsin a downward direction, because of the compression of the Bellevillewashers 724 in response to a force applied by the nut 712 on theclamping lever 702, the deflection pin 720 is pushed downwardly, whichmoves the indicator on the deflection gauge 706. Hold down bolts 733,734 are provided to hold the mounting clamp 700 securely to theconfigurable table 106 (FIG. 6).

FIG. 10 is an isometric sectional view of the mounting clamp 700. Asillustrated in FIG. 10, the clamping lever 702 generates a force on thedeflection plate 722. The deflection plate 722 and the deflection piston730 may comprise a single piece. Forces generated on the deflectionplate 722 and deflection piston 730 are transmitted to the Bellevillewashers 724. The Belleville washers 724 compress and cause thedeflection piston 730 and deflection plate 722, to move downwardlyagainst the deflection pin 720, thereby moving the deflection pin 720 ina downward direction. The deflection gauge 706 is statically mounted sothat the movement of the deflection pin 720 causes an indicator on thedeflection gauge 706 to move. The movement of the deflection pin is anindication of the force generated by the clamping lever 702 on thedeflection plate 722. Hold down bolts 733, 734 hold the mounting clamp700 to the configurable table 106.

The mounting clamp 700, illustrated in FIGS. 7-10, is one example of themanner in which a clamp can be made, which includes a force indicator.Various other types of designs can be employed, such as hydraulically orpneumatically operated clamps, force indicators disposed in datumdevices that indicate the force generated by a pusher, other types ofmechanically operated clamps, etc. In addition, the mounting clamp 700indicates the force that is generated by the clamp by measuring thedeflection of springs, which include Belleville washers. Other types ofsprings can be used and other types of force indicators can be usedbesides deflection gauges, including switch devices that indicate apredetermine deflection. Further, forces can be measured directlywithout measuring deflection, such as by using piezoelectric devices, orother force sensing devices.

FIG. 11 is a isometric view of an embodiment of a crowder 1100. Asillustrated in FIG. 11, crowder 1100 is mounted on the configurabletable 106 (not shown in FIG. 11, but shown in FIG. 6) with hold downbolts 1110, 1112 and generates a force on the work piece 726 (not shownin FIG. 11, but shown in FIG. 9) to position the work piece 726 againsta datum, such as datum 1400, illustrated in FIG. 14. The crowder 1100generates a force in a horizontal direction, which is capable of movingand positioning the work piece 726 against the datum, so that apre-programmed robot can perform welding, machining, cutting, or othertasks at an accurate location on the work piece 726. Once the crowder1100 is bolted to the configurable table 106 (not shown in FIG. 11, butshown in FIG. 6), the tool engaging device 1108 can be rotated, whichcauses the contact surface 1104 of the crowder arm 1102 to engage thework piece 726 on the contact surface 1104 and force the work piece 726into a position on the configurable table 106 against a datum. The toolengaging device 1108 can comprise any desired type of tool engagingdevice, such as the hexagonally shaped portion of the crowder shaft 1126(FIG. 12), socket extension opening, a square shaped driver, or anyother type of tool engaging device. Handle 1106 is releasably connectedto the crowder body housing 1114, which allows the crowder 1100 to belifted and positioned in the proper location for connection to theconfigurable table 106. Handle 1106 can be easily removed from thecrowder body housing 1114 and used with many of the other configurablemounting pieces 108. Additionally, the crowder 1100 can be driven byother means, such as by a hydraulic or pneumatic driver, or other typeof mechanical force generating device.

FIG. 12 is an isometric view of the crowder 1100 illustrated in FIG. 11.As shown in FIG. 12, the bellows and bellows plate have been removed, sothat the crowder shaft 1126 and shaft block 1116 are visible. Thecrowder body housing 1114 has an opening 1118, in which the shaft block1116 is disposed. Both the crowder shaft 1126, as well as the shaftblock 1116, are threaded, so that turning of the crowder shaft 1126causes the crowder shaft 1126 to move laterally with respect to theshaft block 1116. A series of detents 1120, 1122, 1124, as well as anadditional detent not visible in FIG. 12, support the shaft block 1116in the opening 1118 of the crowder body housing 1114, but allow theshaft block to move laterally. In addition, the detents 1120, 1122, 1124keep the shaft block 1116 from rotating in the crowder body housing1114, when the crowder shaft 1126 is turned. In this manner, rotation ofthe tool engaging device 1108 causes the crowder shaft 1126 to extend orretract laterally in the crowder body housing 1114.

FIG. 13 is a side isometric view of the embodiment of FIG. 11,illustrating components of the crowder 1100. As illustrated in FIG. 13,crowder shaft 1126 is threaded through the shaft block 1116. When thecontact surface 1104 pushes against the work piece, the shaft block 1116moves laterally to the right against the Belleville washers 1136, orother spring device. A deflection plate 1130, that is in contact withthe shaft block 1116, also moves with the shaft block 1116. TheBelleville washers 1136 are compressed against a surface of the crowderbody housing 1114 (not shown) and allow the shaft block 1116 and thedeflection plate 1130 to move laterally to the right. This causes thedeflection pin 1134 to be depressed, which causes an indicator on thedeflection gauge 1132 to display the amount of deflection. The amount ofdeflection indicated by the deflection gauge 1108 is proportional to theforce applied by the crowder shaft 1126 on the work piece. In thismanner, an accurate reading of the force can be obtained by thedeflection gauge 1132.

FIG. 14 is an isometric view of an embodiment of a datum 1400. Asillustrated in FIG. 14, the datum 1400 has a base plate 1402 and a holddown bolt 1404 that holds the base plate 1402 to the configurable table106. Another hold down bolt 1414 (FIG. 15) is also used to hold the baseplate 1402 to the configurable table 106. A support plate 1408 isconnected to the base plate 1402 with a connecting plate 1412. A datumplate 1406, made of hardened metal, is coupled to the support plate1408. The surface of the datum plate provides a datum point toaccurately locate the work piece with respect to the configurable table106. Handle 1410 is used to lift and transport the datum 1400 and can beremoved after the datum 1400 is placed on the configurable table 106.

FIG. 15 is a side isometric view of the datum 1400 illustrated in FIG.14. As shown in FIG. 15, hold down bolts 1404, 1414 hold the base plate1402 to the configurable table 106 (FIG. 1). Connecting plate 1412 andanother connecting plate (not shown) connect the support plate 1408 tothe base plate 1402 and provide additional support for the support plate1408 when large pressures are applied to the datum plate 1406. Inaddition, the support plate 1408 is welded to the base plate 1402 toassist in securely attaching the support plate 1408 to the base plate1402.

As also illustrated in FIG. 15, the datum 1400 includes bushings 1416,1418. These bushings are mounted in recesses in the configurable table,such as configurable table 106 (FIG. 1), to accurately locate the datum1400 with respect to the surface of the configurable table 106. Forexample, the threaded openings 128, illustrated in FIG. 4, may include arecess that is not threaded on a top portion of the top plate 130 (FIG.4) that closely matches the dimensions of the bushings 1416, 1418 toprecisely locate the datum 1400 on the configurable table 106. Since thehold down bolts 1414, 1404 may have play associated with the openings inthe base plate 1402, the hold down bolts 1414, 1404 may not provide theprecise positioning of the datum 1400 on the configurable table 106. Ofcourse, each datum, such as datums 110, 112, illustrated in FIG. 1, aswell as all of the configurable pieces 108, can include bushings, suchas bushings 1416, 1418 to accurately locate the configurable mountingpieces 108 on the configurable table 106.

FIG. 16 is an isometric view of an embodiment of a combined clamp andcrowder. As shown in FIG. 16, a base 1608 is attached to a base plate1601. Hold down bolts 1610, 1612, 1614 secure the base plate 1601 andthe base 1608 to the configurable table 106 (FIG. 1). Another hold downbolt (not shown) is also used to secure the base plate 1601 to theconfigurable table 106. Base 1608 supports clamp 1602, crowder 1604 andcrowder 1606. Crowder 1604 and crowder 1606 apply a force to the workpiece to ensure that the work piece is securely positioned against atleast two datums (not shown). Clamp 1602 secures the work piece to theconfigurable table 106 and substantially prevents movement of the workpiece with respect to the configurable table 106. Of course, any desiredconfiguration of clamps, crowders and datums can be used to position andsecure a work piece to a configurable table, such as configurable table106.

FIG. 17 is an isometric diagram of a horizontally disposed datum 1700.The horizontally disposed datum 1700 is substantially parallel to thesurface of the configurable table 1706 and provides a datum plane forvertically locating a work piece. The datum plate 1702 is supported by abase 1704 that is welded or otherwise attached to a base plate 1710. Thebase plate 1710 is attached to the configurable table 1706 with bolts(not shown) that engage the threaded opening 1708. As also shown in FIG.17, the openings have a recessed portion 1710 and a threaded portion1712. As disclosed above, the recessed portion 1710 matches thebushings, such as bushings 1416, 1418 (FIG. 15) to precisely locate thedatum or other configurable mounting pieces on the configurable mountingtable 1706. Again, the tolerances of the recessed portion 1710 and thebushings on the datum, such as horizontal datum 1700, are closelymatched, so that the horizontal datum 1700 is accurately located on theconfigurable table 1706.

FIG. 18 is an isometric view of a custom mounting design 1800. As shownin FIG. 18, a work piece 1802 is positioned and attached to theconfigurable table 1810 using crowder 1808. In addition, custom mountingclamp 1804 and custom mounting clamp base 1806 secure the work piece1802 to the configurable table 1810. The configuration illustrated inthe custom mounting assembly 1800 shows the manner in which uniquecustom work pieces can be secured to the configurable table 1810 invarious ways.

FIG. 19 is an illustration of the configurable mounting pieces utilizedin the custom mounting design illustrated in FIG. 18. As shown in FIG.19, the custom mounting base 1806 holds the work piece 1802 in position,while the custom mounting clamp 1804 secures the work piece 1802 to thecustom mounting clamp base 1806. Datums 1812, 1814, 1816 accuratelylocate the other end of the work piece 1802 on the configurable table1810. In this manner, the work piece 1802 is both secured and accuratelylocated on the configurable table 1810.

FIG. 20 is an illustration of another embodiment that uses positionersin conjunction with a configurable table. As illustrated in FIG. 20, aconfigurable table 2000, such as described above, can be mounted topositioners 2006, 2008, with quick release clamps 2002, 2004. As shownin FIG. 20, the configurable table 2000 can be rotated around a singleaxis, together with a work piece that is secured to the configurabletable 2000. In fact, the configurable table 2000 can be attached usingquick release clamps, such as quick release clamps 2002, 2004 on anyportion of the configurable table to provide the desired rotation of thework piece for robotic welding. Any desired type of release clamp can beused, including quick release clamps, such as quick release clamps 2002,2004, or the rotatable mounting clamp 118, illustrated in FIG. 2.Non-quick release clamps can also be used. Further, the positioners2006, 2008 can be mounted on a positioning arm to provide another axisof rotation. In this manner, a work piece mounted on the configurabletable 2000 can be positioned as desired for robotic welding.

FIG. 21 is an isometric view of an embodiment of a head end or tail endclamp 2100. The head end or tail end clamp 2100 is connected to apositioning arm by way of plate 2102. Mount 2104 is used to mount eithera work piece or a configurable table, such as configurable table 2000,illustrated in FIG. 20. Clamps 2106, 2108 clamp the work piece orconfigurable table to the head end or tail end clamp 2100. A forceindicator 2110 indicates the clamping force that is generated by clamps2106, 2108 to hold the work piece or configurable table securely to thehead end or tail end clamp 2100. Accordingly, force indicators, such asdeflection dials and other indicating devices, can be used in themounting clamps to provide a visual indication or other indication thatsufficient clamping force has been generated by the mounting clamp.

Hence, the embodiments illustrated herein are capable of locating andsecuring large and heavy work pieces on a configurable table usingconfigurable mounting pieces. The configurable mounting piecesadditionally provide an indication of a proper clamping force, usingintegrated force meters. The configurable mounting pieces include datumsand crowders for accurately positioning the work piece on theconfigurable table. The configurable table includes a fixed portion of amounting clamp that interfaces with a moveable portion of a mountingclamp that can be located on a positioner, so that the work piece can bemoved in various orientations for machining, cutting and welding. Sincewelds are ideally performed in a horizontal orientation, a positionercan be used to perform automated welding using robotic welding devicesthat perform the welding processes when the positioner places the weldin a horizontal orientation. In this manner, high quality and consistentwelds can be performed. In addition, the configurable table 106 can beused for initial fabrication prior to robotic finish welding, so that aseparate fabrication table does not have to be employed and bothfabrication and finish welding can be performed on a single table. Theconfigurable mounting pieces generate a consistent and adequate force tohold the work piece to the configurable table, while the work piece isrotated into various orientations. The two-piece rotatable mountingclamp allows multiple tables to be used with a single positioner, withthe less expensive fixed portion disposed on the configurable table. Inthis manner, efficiency is increased by allowing multiple stages offabrication on multiple tables to occur simultaneously. The Bellevillewashers disclosed herein can be replaced with various types of springs.For example, a coil spring can be used that has a linear response in therange of forces to be asserted by the clamp or crowder, so that asubstantially linear measurement of force can be detected using adeflection gauge. Other types of spring washers, as well as other springdevices can be utilized to create a substantially linear deflectionversus force curve in the contemplated force ranges.

The foregoing description of the invention has been presented forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention to the precise form disclosed, andother modifications and variations may be possible in light of the aboveteachings. The embodiment was chosen and described in order to bestexplain the principles of the invention and its practical application tothereby enable others skilled in the art to best utilize the inventionin various embodiments and various modifications as are suited to theparticular use contemplated. It is intended that the appended claims beconstrued to include other alternative embodiments of the inventionexcept insofar as limited by the prior art.

What is claimed is:
 1. A method of configuring a work piece forperforming a work task comprising: providing a configurable table havinga plurality of mounting locations disposed on a first portion of saidconfigurable table and a first portion of a rotatable mounting clampdisposed on a second portion of said configurable table; providing aplurality of configurable mounting pieces having mounting connectors formounting said mounting pieces at said mounting locations disposed onsaid first surface of said configurable table, said configurablemounting pieces adapted to position and mount said work piece in apredetermined location on said configurable table; and providing asecond portion of said rotatable mounting clamp that is designed toengage said first portion of said rotatable mounting clamp withsufficient force so that said configurable table can be rotated withsaid work piece mounted on said configurable table in said predeterminedposition with sufficient force so that said work piece does notsubstantially move with respect to said configurable table.
 2. Themethod of claim 1 further comprising: providing a positioner having saidsecond portion of said mounting clamp mounted on said positioner; andmounting said configurable table to said positioner by engaging saidfirst portion of said rotatable mounting clamp with said second portionof said rotatable mounting clamp.
 3. The method of claim 2 furthercomprising: mounting said work piece to said configurable table usingsaid configurable mounting pieces so that said work piece is securelydisposed in said predetermined location on said configurable table; androtating said configurable table using said positioner so that said workpiece is positioned to perform said work task, said configurablemounting pieces securely holding said work piece on said configurabletable so that said work piece does not substantially move with respectto said configurable table when said positioner rotates saidconfigurable table to perform said work task.
 4. The method of claim 3wherein said process of providing a plurality of configurable mountingpieces comprises: providing at least one clamp that securely holds saidwork piece to said configurable table.
 5. The method of claim 4 whereinsaid process of providing a plurality of configurable mounting piecesfurther comprises: providing at least one crowder that accuratelypositions said work piece on said configurable table.
 6. The method ofclaim 5 wherein said process of providing a plurality of configurablemounting pieces comprises: providing at least one datum that furtheraccurately positions said work piece on said configurable table.
 7. Themethod of claim 6 wherein said work task comprises welding.
 8. Themethod of claim 6 wherein said work task comprises machining.
 9. Asystem for configuring a work piece for a work task comprising: aconfigurable table having a plurality of mounting locations disposed ona first portion of said configurable table; a first portion of arotatable mounting clamp disposed on a second portion of saidconfigurable table; a plurality of configurable mounting pieces that areadapted to position and securely mount said work piece to said firstportion of said configurable table; a plurality of mounting connectorsthat engage said mounting locations disposed on said first portion ofsaid configurable table to securely mount said configurable mountingpieces to said first portion of said configurable table; and a secondportion of said rotatable mounting clamp that engages said rotatablemounting clamp and that is configured to engage said first portion ofsaid rotatable mounting clamp with sufficient force to rotate and invertsaid work piece.
 10. A crowder for mounting and positioning a work pieceto a configurable table comprising: a base plate that is adapted tosecure said crowder to said configurable table; a crowder body housing;a threaded shaft block disposed in said crowder body so that said shaftblock can move laterally in said crowder body; a threaded shaft thatrotatably engages said shaft block and applies a force on said workpiece in response to rotation of said shaft which causes threaded shaftblock to translate laterally; a spring that compresses in response tolateral translation of said threaded shaft block; and a deflection gaugethat measures said lateral translation of said shaft block to provide ameasurement of said force applied to said work piece.
 11. The crowder ofclaim 10 wherein said spring comprises a plurality of spring washers.12. The crowder of claim 10 further comprising: a tool engaging devicecoupled to said threaded shaft for rotating said threaded shaft.
 13. Asystem for configuring a work piece for a work task comprising: aconfigurable table having a plurality of mounting locations disposed ona first portion of said configurable table; a plurality of configurablemounting pieces that position and securely mount said work piece to saidfirst portion of said configurable table with sufficient force to holdsaid work piece to said configurable table without substantial movementwhen said work piece is rotated; and a plurality of mounting connectorsthat engage said plurality of configurable mounting pieces and saidmounting locations disposed on said first portion of said configurabletable to securely mount said plurality of configurable mounting piecesto said first portion of said configurable table.